Imaged nonwoven fire-retardant fiber blends and process for making same

Abstract

The present invention is directed to a durable and imaged flame-retardant nonwoven fabric that can be used for flame-retardant apparel and other related applications. The fabric is formed by providing a precursor web consisting of a blend of melamine fibers and aramid fibers. The precursor web is hydroentangled on a three-dimensional image transfer device for formation of the fabric. The resultant fabric provides desirable air permeability and Thermal Protective Properties.

What is claimed is:  
     
       1. An entangled nonwoven fabric with thermal protective properties formed by a process comprising the steps of: 
       providing a precursor web consisting of a fiber blend of melamine fibers and aramid fibers, said blend comprising between 45 weight percent and 55 weight percent melamine fibers,  
       entangling said precursor web with high pressure water jets to form a pre-entangled precursor web,  
       directing said pre-entangled precursor web onto a three-dimensional image transfer device having a three-dimensional imaging surface,  
       and applying water under high pressure to impart an image of said imaging surface to the pre-entangled precursor web to form said entangled nonwoven fabric,  
       said entangled nonwoven fabric having an air permeability rating of greater than 65 CFM per gram of fabric weight per cubic centimeter and a thermal protective property rating of at least 11.4 calorie-seconds per square centimeter.  
     
     
       2. A fabric according to  claim 1  having a fiber blend comprising about 50 weight percent melamine fibers. 
     
     
       3. A fabric according to  claim 1  having a having a basis weight in the range of 65 gsm to 150 gsm. 
     
     
       4. A thermal protection fabric comprised of a precursor web consisting of a blend of melamine fibers and aramid fibers, the precursor web being pre-entangled with high pressure water jets, and thereafter directed onto a imaging member having a three-dimensional imaging surface, with water under high pressure applied thereto to impart an image of said imaging surface to the pre-entangled precursor web such that the final resultant fabric has a fiber blend comprising about 50 weight percent melamine fibers, a basis weight in the range of 65 gsm to 150 gsm, an air permeability rating of greater than 65 CFM per gram of fabric weight per cubic centimeter and a thermal protective property rating of at least 11.4 calorie-seconds per square centimeter. 
     
     
       5. A fabric of  claim 4 , wherein said fabric is configured as an article of flame retardant apparel. 
     
     
       6. A fabric of  claim 4 , wherein said fabric is configured as a thermal protective blankets. 
     
     
       7. A fabric of  claim 4 , wherein said fabric is configured as one of a drapery or drapery lining.